Organic carbonate plasticized polycarbonate composition

ABSTRACT

A plasticized polycarbonate composition comprising in admixture a high molecular weight aromatic carbonate polymer and a minor amount of an organic carbonate.

This invention is directed to a plasticized polycarbonate compositioncomprising in admixture a high molecular weight aromatic carbonatepolymer and a minor amount of an organic carbonate.

BACKGROUND OF THE INVENTION

Polycarbonate polymers are excellent molding materials as products madetherefrom have high impact strength, toughness, high transparency, widetemperature limits (high impact resistance below -60° C and a UL thermalendurance rating of 115° C with impact), good dimensional stability,high creep resistance and electrical properties which qualify it as solesupport for current carrying parts.

Polycarbonates are, however, very difficult to fabricate from melts forthe reason that melts thereof have exceptionally high viscosities.Attempts to overcome this difficulty by the incorporation with thepolycarbonate of materials known to reduce the viscosity of other resinshave very generally been unsuccessful. Many standard viscosity controlagents appear to have little or no effect on the viscosity ofpolycarbonate. Other compounds known to lower the viscosity of resinscause degradation of polycarbonate resins. Some compounds,conventionally employed to improve the workability of polymers, producean embrittling effect on polycarbonates when they are mixed therewithand the resin is subjected to elevated temperatures as in molding. Stillother materials, while satisfactory stiffness modifying agents for otherplastics, are too volatile to be incorporated with polycarbonates sincepolycarbonates have much higher melting points than many otherthermoplastics.

From U.S. Pat. No. 3,269,971, it is known that particular carbonateesters when added to aromatic polycarbonates act as plasticizers.

DESCRIPTION OF THE INVENTION

It has been surprisingly discovered that, by admixing a minor amount ofan organic carbonate with a high molecular weight aromatic carbonatepolymer, the resultant polycarbonate composition has reduced meltviscosity and does not become brittle or degraded upon molding and thusretains its characteristic high impact strength.

In the practice of this invention, the organic carbonate additive ischaracterized by the following formula: ##STR1## wherein R and R" areindependently selected from the group consisting of C₁ to C₃₀ alkyl,aryl of 6 to 14 carbon atoms and substituted aryl wherein thesubstituents are C₁ to C₃₀ alkyl, halogen, C₁ to C₃₀ alkoxy, aryloxy of6 to 14 carbon atoms, alkylthio of 1 to 30 carbon atoms, arylthio of 6to 14 carbon atoms, R' is selected from the group consisting of C₁ toC₃₀ alkylene, arylene of 6 to 14 carbon atoms, alkarylene of 7 to 30carbon atoms, aralkylene of 7 to 30 carbon atoms and ##STR2## wherein Wis selected from the group consisting of: ##STR3## wherein A is ##STR4##and R₄ is hydrogen or C₁ -C₄ alkyl; R is independently selected from thegroup consisting of hydrogen, C₁ -C₁₅ alkyl, aryl of 6-14 carbon atomsand substituted aryl wherein the substituents are C₁ -C₅ alkyl;

(b) --CH₂ CH₂ --;

(c) --CH₂ B-CH₂ --;

wherein B is C₁ -C₁₆ alkylene or arylene of 6 to 14 carbon atoms;##STR5## wherein a is an integer of 3 to 15; (e) --O--;

(f) --S--; ##STR6## X and Y are independently selected from the groupconsisting of halogen and C₁ -C₁₂ alkyl; n is 0 or 1 with the provisothat when n is 0 at least one of R or R" is substituted aryl wherein thesubstituents are C₁ to C₃₀ alkoxy, aryloxy of 6 to 14 carbon atoms,alkylthio of 1 to 30 carbon atoms and arylthio of 6 to 14 carbon atoms.

The amount of organic carbonate employed in the practice of thisinvention may vary from 0.05 to about 5.0 parts per hundred parts ofaromatic carbonate polymer. Preferably, these carbonate esters areemployed in amounts of from 0.25 to 2.0 parts per hundred parts ofaromatic carbonate polymer.

In the practice of this invention, the high molecular weight aromaticpolycarbonates that can be employed herein are homopolymers andcopolymers and mixtures thereof which have an I.V. of 0.40 to 1.0 dl./g.as measured in methylene chloride at 25° C that are prepared by reactinga dihydric phenol with a carbonate precursor. Typical of some of thedihydric phenols that may be employed in the practice of this inventionare bisphenol-A, (2,2-bis(4-hydroxyphenyl)propane), bis(4-hydroxyphenyl)methane, 2,2-bis(4-hydroxy-3-methylphenyl) propane,4,4-bis(4-hydroxyphenyl) heptane,2,2-(3,5,3',5'-tetrachloro-4,4'-dihydroxydiphenyl) propane,2,2-(3,5,3',5'-tetrabromo-4,4'-dihydroxydiphenyl) propane,(3,3'-dichloro-4,4'-dihydroxydiphenyl)methane. Other dihydric phenols ofthe bisphenol type are also available and are disclosed in U.S. Pat.Nos. 2,999,835, 3,028,365 and 3,334,154.

It is, of course, possible to employ two or more different dihydricphenols or a copolymer of a dihydric phenol with a glycol or withhydroxy or acid terminated polyester, or with a dibasic acid in theevent a carbonate copolymer or interpolymer rather than a homopolymer isdesired for use in the preparation of the aromatic carbonate polymers ofthis invention. Also employed in the practice of this invention may beblends of any of the above materials to provide the aromatic carbonatepolymer.

The carbonate precursor may be either a carbonyl halide, a carbonateester or a haloformate. The carbonyl halides which can be employedherein are carbonyl bromide, carbonyl chloride and mixtures thereof.Typical of the carbonate esters which may be employed herein arediphenyl carbonate, di-(halophenyl) carbonates such as di-(chlorophenyl)carbonate, di-(bromophenyl) carbonate, di-(trichlorophenyl) carbonate,di-(tribromophenyl) carbonate, etc., di-(alkylphenyl) carbonates such asdi(tolyl) carbonate, etc., di-(naphthyl) carbonate, di-(chloronaphthyl)carbonate, phenyl tolyl carbonate, chlorophenyl chloronaphthylcarbonate, etc., or mixtures thereof. The haloformates suitable for useherein include bis-haloformates of dihydric phenols (bischloroformatesof hydroquinone, etc.) or glycols (bishaloformates of ethylene glycol,neopentyl glycol, polyethylene glycol, etc.). While other carbonateprecursors will occur to those skilled in the art, carbonyl chloride,also known as phosgene, is preferred.

Also included are the polymeric derivatives of a dihydric phenol, adicarboxylic acid and carbonic acid. These are disclosed in U.S. Pat.No. 3,169,121 which is incorporated herein by reference.

The aromatic carbonate polymers of this invention may be prepared byemploying a molecular weight regulator, an acid acceptor and a catalyst.The molecular weight regulators which can be employed in carrying outthe process of this invention include monohydric phenols such as phenol,chroman-I, paratertiarybutylphenol, parabromophenol, primary andsecondary amines, etc. Preferably, phenol is employed as the molecularweight regulator.

A suitable acid acceptor may be either an organic or an inorganic acidacceptor. A suitable organic acid acceptor is a tertiary amine andincludes such materials as pyridine, triethylamine, dimethylamiline,tributylamine, etc. The inorganic acid acceptor may be one which can beeither a hydroxide, a carbonate, a bicarbonate, or a phosphate of analkali or alkaline earth metal.

The catalysts which are employed herein can be any of the suitablecatalysts that aid the polymerization of bisphenol-A with phosgene.Suitable catalysts include tertiary amines such as, for example,triethylamine, tripropylamine, N,N-dimethylaniline, quaternary ammoniumcompounds such as, for example, tetraethylammonium bromide, cetyltriethyl ammonium bromide, tetra-n-heptylammonium iodide, tetra-n-propylammonium bromide, tetramethylammonium chloride, tetramethyl ammoniumhydroxide, tetra-n-butyl ammonium iodide, benzyltrimethyl ammoniumchloride and quaternary phosphonium compounds such as, for example,n-butyltriphenyl phosphonium bromide and methyltriphenyl phosphoniumbromide.

Also, included herein are branched polycarbonates wherein apolyfunctional aromatic compound is reacted with the dihydric phenol andcarbonate precursor to provide a thermoplastic randomly branchedpolycarbonate.

These polyfunctional aromatic compounds contain at least threefunctional groups which are carboxyl, carboxylic anhydride, haloformylor mixtures thereof. Examples of these polyfunctional aromatic compoundswhich may be employed in the practice of this invention include:trimellitic anhydride, trimellitic acid, trimellityl trichloride,4-chloroformyl phthalic anhydride, pyromellitic acid, pyromelliticdianhydride, mellitic acid, mellitic anhydride, trimesic acid,benzophenonetetracarboxylic acid, benzophenonetetracarboxylic anhydrideand the like. The preferred polyfunctional aromatic compounds aretrimellitic anhydride or trimellitic acids or their haloformylderivatives.

Also, included herein are blends of a linear polycarbonate and abranched polycarbonate.

The composition of the instant invention may be prepared by blending thehigh molecular weight aromatic polycarbonate with the additive byconventional methods.

Obviously, other materials can also be employed with the aromaticcarbonate polymer of this invention and include such materials asanti-static agents, pigments, thermal stabilizers, ultravioletstabilizers, reinforcing fillers and the like.

PREFERRED EMBODIMENT OF THE INVENTION

In order to more fully and clearly illustrate the present invention, thefollowing specific examples are presented. It is intended that theexamples be considered as illustrative rather than limiting theinvention disclosed and claimed herein. In the examples, all parts andpercentages are on a weight basis unless otherwise specified.

EXAMPLE I

One hundred (100) parts of an aromatic polycarbonate, prepared from2,2-bis(4-hydroxyphenyl) propane and phosgene in the presence of an acidacceptor and a molecular weight regulator and having an intrinsicviscosity of about 0.57, is mixed with the additive listed in the Tableby tumbling the ingredients together in a laboratory tumbler. Theresulting mixture is then fed to an extruder which is operated at about265° C, and the extrudate is comminuted into pellets.

The pellets are then fed into a plastometer and the flow rate of thepolymer is measured according to ASTM D1238-70, Condition 0. The meltflow rate is set forth in the Table.

Additionally, the pellets are injection molded at about 315° C into testspecimens of about 5 by 1/2 by 1/8 inch thick. The impact strength ofthese specimens is then measured according to the Izod test, ASTM D-256.The impact strength is set forth in the Table. The sample labeledCONTROL is the polycarbonate as prepared without additive.

                                      Table                                       __________________________________________________________________________                                             Amt. of Melt   Impact                                                         Additive (Parts                                                                       Flow Rate                                                                            Strength              Additive                                 per Hundred)                                                                          (gr./10                                                                              (Ft.Lbs./In.)         __________________________________________________________________________    CONTROL                                  --      10.0   15.0                   ##STR7##                                1.0     13.94  13.9                   ##STR8##                                0.5     13.26  14.6                   ##STR9##                                1.0     13.60  13.2                   ##STR10##                               0.2     13.26  15.0                   ##STR11##                               0.5     15.74  14.6                   ##STR12##                               0.1     11.73  15.4                   ##STR13##                               0.5     12.63  10.9                   ##STR14##                               2.0     17.35  11.3                  __________________________________________________________________________

It can be seen from the data in the Table that when the instant organiccarbonate additive is added to a high molecular weight aromaticpolycarbonate, the resulting polycarbonate composition has reduced meltviscosity as shown by the higher melt flow rate while retaining impactstrength.

It will thus be seen that the objects set forth above among those madeapparent from the preceding description are efficiently attained andsince certain changes may be made in carrying out the above process andin the composition set forth without departing from the scope of thisinvention, it is intended that all matters contained in the abovedescription shall be interpreted as illustrative and not in a limitingsense.

What is claimed is:
 1. A plasticized polycarbonate compositioncomprising in admixture homopolymers, copolymers and mixtures thereof ofa high molecular weight aromatic carbonate polymer having an I.V. of0.40 to 1.0 dl/g in methylene chloride at 25° C. and a minor amount ofan organic carbonate of the following formula: ##STR15## wherein R andR" are independently selected from the group consisting of C₁ of C₃₀alkyl, aryl of 6 to 14 carbon atoms and substituted aryl wherein thesubstituents are C₁ and to C₃₀ alkyl, halogen, C₁ to C₃₀ alkoxy, aryloxyof 6 to 14 carbon atoms, alkylthio of 1 to 30 carbon atoms, arylthio of6 to 14 carbon atoms, R' is selected from the group consisting of C₁ toC₃₀ alkylene, arylene of 6 to 14 carbon atoms, alkarylene of 7 to 30carbon atoms, aralkylene of 7 to 30 carbon atoms and ##STR16## wherein Wis selected from the group consisting of ##STR17## wherein A is##STR18## and R₄ is hydrogen of C₁ -C₄ alkyl; R is independentlyselected from the group consisting of hydrogen, C₁ -C₁₅ alkyl, aryl of6-14 carbon atoms and substituted aryl wherein the substituents are C₁-C₁₅ alkyl;(b) --CH₂ CH₂ -- (c) --CH₂ B-CH₂ --wherein B is C₁ -C₁₆alkylene or arylene of 6 to 14 carbon atoms; ##STR19## wherein a is aninteger of 3 to 15; (e) --O--; (f) --S--; ##STR20## X and Y areindependently selected from the group consisting of halogen and C₁ -C₁₂alkyl; n is 0 or 1 with the proviso that when n is 0 at least one of Ror R" is substituted aryl wherein the substituents are C₁ to C₃₀ alkoxy,aryloxy of 6 to 14 carbon atoms, alkylthio of 1 to 30 carbon atoms andarylthio of 6 to 14 carbon atoms.
 2. The composition of claim 1 whereinthe organic carbonate is present in an amount of from 0.05 to about 5.0parts per hundred parts of aromatic carbonate polymer.
 3. Thecomposition of claim 1 wherein the aromatic carbonate polymer is derivedfrom bisphenol-A.
 4. The composition of claim 1 wherein the aromaticcarbonate polymer is a copolymer derived from bisphenol-A and tetrabromobisphenol-A.
 5. The composition of claim 1 wherein the organic carbonatehas the following formula: ##STR21##
 6. The composition of claim 1wherein the organic carbonate has the following formula: ##STR22## 7.The composition of claim 1 wherein the organic carbonate has thefollowing formula: ##STR23##
 8. The composition of claim 1 wherein theorganic carbonate has the following formula: ##STR24##